Coiled tubing/top drive rig and method

ABSTRACT

The rig for selectively inserting coiled tubing or a threaded tubular through a rig floor  13  and into a well includes a mast  15  extending upward from the rig floor and movable between a threaded tubular position and a coiled tubing position. A top drive  21  is movable along an axis of the mast to insert the threaded tubular in the well when a top drive axis  42  is substantially aligned with the axis  44  of the well. Injector  17  supported on the mast inserts coiled tubing into the well, with the injector having an axis  46  offset from the top drive axis and substantially aligned with the axis of the well when the mast is in the coiled tubing position. A powered drive  54  is provided for selectively moving the mast between the threaded tubular position and the coiled tubing position.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/294,036 filed Dec. 5, 2005 now U.S. Pat. No. 7,185,708 for COILEDTUBING/TOP DRIVE RIG AND METHOD, which is in turn a continuation-in-partof U.S. patent application Ser. No. 11/165,931, filed Jun. 24, 2005, nowU.S. Pat. No. 7,182,140 each incorporated herein in their entirety forall purposes.

FIELD OF THE INVENTION

The invention relates to methods and apparatus for performing earthborehole operations, such as drilling, and in particular to methods andapparatus which can use either coiled tubing or threaded pipe.

BACKGROUND OF THE INVENTION

The use of coiled tubing (CT) technology in oil and gas drilling andservicing has become more and more common in the last few years. In CTtechnology, a continuous pipe wound on a spool is straightened andpushed down a well using a CT injector. CT technology can be used forboth drilling and servicing operations.

The advantages offered by the use of CT technology, including economy oftime and cost, are well known. As compared with jointed-pipe technologywherein typically 30-45 foot straight sections of pipe are threadedlyconnected one section at a time, CT technology allows the continuousdeployment of pipe, significantly reducing the frequency with which pipeinsertion into the well must be suspended to allow additional sectionsof pipe to be connected. This results in less connection time, and as aresult, an efficiency of both cost and time. CT technology also allowsfluid to be continuously circulated downhole while inserting the tubularin the well, thereby significantly reducing the likelihood of a stucktubular.

The adoption of CT technology has been less widespread than originallyanticipated as a result of certain problems inherent in using CT. Forexample, because CT tends to be less robust than threaded pipe, it isoften necessary to drill a surface hole using threaded pipe, cementcasing into the surface hole, and then switch over to CT drilling.Additionally, when difficult rock formations are encountered downhole,it may be desirable to switch from CT drilling to threaded pipe drillinguntil drilling through the difficult formation is complete, and thenswitch back to CT drilling to continue efficiently drilling the well.Similarly, when it is necessary to perform drill stem testing or coringoperations to assess conditions downhole, it may again be desirable toswitch from CT to threaded pipe and then back again. A switch back tothreaded pipe operations may also be desirable to run casing into thedrilled well. When conducting CT drilling operations, it is frequentlydesirable to switch back and forth between a CT drilling rig and athreaded pipe conventional drilling rig, a process which results insignificant costs for two rigs and down time as one rig is moved out ofthe way, and another rig put in place.

A disadvantage of CT drilling is the time-consuming process ofassembling a bottom-hole-assembly (BHA)—the components at the end of theCT for drilling, testing, well servicing, etc., and connecting the BHAto the end of the CT. Presently, this operation is commonly performedmanually through the use of rotary tables and make-up/breakoutequipment. In some instances, top drives are used, but one of the CTinjector or the top drive must be moved out, i.e., they cannot both bein line with the borehole. Not only does this process result in costlydowntime, but it can also present safety hazards to the workers as theymanipulate heavy components manually.

U.S. Publication 2004/0206551 discloses a rig adapted to perform earthborehole operations using both CT and/or threaded pipe, the CT injectorand a top drive being mounted on the same mast. The CT injector isselectively moveable with respect to the mast between a first positionwherein the CT injector is in line with the mast of the rig and hencethe earth borehole and a second position wherein the CT injector is outof line with the mast to allow threaded pipe operations using the topdrive.

The disadvantages of the prior art are overcome by the presentinvention, and an improved rig and method for selectively insertingeither coiled tubing or a threaded tubular into a well utilizing acoiled tubing injector or a top drive, respectively, is hereinafterdisclosed.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a rig for selectivelyinserting coiled tubing or a threaded tubular through a rig floor andinto a well. The rig includes a mast extending upward from the rig floorand movable between a threaded tubular position and a coiled tubingposition. A top drive is movable along an axis of the mast to insert thethreaded tubular into the well, with a top drive having a top drive axissubstantially aligned with an axis of the well when the mast is in thethreaded tubular position. An injector supported on the mast is alsoprovided to insert the coiled tubing into the well, with the injectorhaving an injector axis offset from the top drive axis and substantiallyaligned with the axis of the well when the mast is in the coiled tubingposition. A powered drive is used to selectively move the mast betweenthe threaded tubular position and the coiled tubing position.

In another aspect of the invention, the mast is pivotally movable withrespect to the rig floor between a threaded tubular position and acoiled tubing position. An injector may be secured to the mast by asupport bracket, or a slide supported on the mast may be provided forguiding vertical movement of the injector relative to the rig floor whenthe mast is in the coiled tubing position.

In another embodiment, a rig for selectively inserting coiled tubing ora threaded tubular through a rig floor and into a well includes a mast,a top drive and an injector. A connector is provided for removablyconnecting the mast to the injector, and a powered drive selectivelyraises the mast and the injector supported on the mast, and the same oranother drive moves the mast between a threaded tubular position and acoiled tubing position. The injector and a coiled tubing reel may besupported on a trailer separate from the rig base during transportation,and a powered lift may be used for raising the injector for connectionwith the mast. The mast may be pivotally movable with respect to the rigbase between the threaded tubular position and the coiled tubingposition. In one embodiment, a fluid powered cylinder is provided formoving the injector relative to the mast and connecting the mast and theinjector.

Further features and advantages of the present invention will becomeapparent from the following detailed description, wherein reference ismade to the figures in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of one embodiment of the presentinvention including a top drive supported on a mast and aligned with awellbore.

FIG. 2 illustrates the rig as shown in FIG. 1, with the mast moved tothe coiled tubing position so that the centerline of the injector isaligned with the wellbore.

FIG. 3 is a side elevational view of another rig according to theinvention, and the centerline of the injector aligned with the wellboreand the injector vertically movable along a slide supported on the mast.

FIG. 4 illustrates another embodiment of the invention, with the topdrive supported on a mast and aligned with the wellbore.

FIG. 5 illustrates the rig as shown in FIG. 4, with the mast movedlaterally so that the centerline of the injector is aligned with thecenterline of the wellbore.

FIG. 6 is a cross section along lines 6-6 in the FIG. 5, showing furtherdetails of the mast positioning mechanism.

FIG. 7 illustrates a mast supported on a rig base, and a tubing reelsupported on a trailer structurally separate from the rig base forproviding coiled tubing to the injector while supported on the mast.

FIG. 8 illustrates a mast pivoted downward relative to the rig base, andthe trailer separate from the rig base supporting a coiled tubing reeland an injector, with the injector raised for connection to the mast.

FIG. 9 illustrates the mast fully lowered on the rig base.

FIG. 10 illustrates a mast moved laterally in respect to the rig basefor being supported by a mast trailer separate from the rig base fortransportation.

FIGS. 11 and 12 illustrate an adjustment mechanism on the trailer foradjusting the position of the injector relative to the mast tofacilitate the connection of the injector and the mast.

FIG. 13 illustrates an alternate embodiment wherein the mast is movedlaterally relative to a rig base between a coiled tubing position and athreaded tubular position after the mast is used to pick up theinjector.

FIG. 14 illustrates yet another embodiment wherein the injector isprovided with a lubricator axis offset from the mast for conductingcoiled tubing operations after the mast is used to pick up the injector.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, one embodiment of the rig includes a mast 15, aworking platform 12, and a rig floor 13. Mast 15 is comprised of a pairof spaced elongate frame members 32 interconnected at the top by a crown22. It should be understood that the figures are for simplicity and thatthe mast and the rig may take various structural forms. Mast 15 ispivotally connected to platform 12, as described below. As shown in FIG.1, the platform 12 is supported on a wheeled carrier or trailer 1 havinga relatively low carrier surface 3. The wheeled carrier 1 may alsoinclude a tongue 2 which may be attached to a motorized vehicle, suchthat the trailer 1 may be moved from one location to another. It will beappreciated that the wheeled carrier 1 may alternatively be selfpropelled, or that the carrier may comprise a stationary structure as,for example, a skid or the like which can be raised and placed on atrailer or other transport vehicle for movement to another site. It willalso be appreciated that the rig of the present invention could bemounted on an offshore platform via a skid or other substructure onwhich the mast and other components are mounted. Wheeled trailer 1 alsoprovides a second, rear platform on which a rotary table 14 is provided,with rig floor 13 defined by platform 12. Working platform 12, whichpreferably may be raised above carrier 1, provides a rig floor 13 forworkers to manipulate various downhole components into and out of therotary table 14 on the working platform, and enables workers to performother normal operations in conjunction with earth borehole operationssuch as drilling, workover, servicing, etc.

Rotatably mounted on the trailer 1 is a spool 4 upon which is wound alength of coiled tubing 30. Spool 4 can be rotated in a clockwise andcounterclockwise directions using a suitable drive assembly (not shown).Also located on trailer 1 is an engine 7 and a hydraulic tank 8 forstorage of hydraulic fluid used in operating the various hydrauliccomponents of the rig, e.g., motors, hydraulic cylinders, etc. As iswell known, most of the components of the rig may be operatedhydraulically, electrically or, in some cases, pneumatically. Coiledtubing 30 extends up to a gooseneck or guide arch 34. The gooseneck 34is attached to the top of coiled tubing injector 17 which, as shown inFIG. 1, is spaced from the mast 15. Coiled tubing injector 17 typicallycomprises a series of blocks, sprockets or like grippers driven byendless chains or belts which grab the coiled tubing 30 and manipulateit downwardly when it is being injected into a well and pull it upwardlywhen it is being removed from the well.

As shown in FIG. 1, a top drive 21 is mounted on mast 15 between members32 for longitudinal movement therealong in either direction. Typically,top drive 21 is mounted on a track system, which is affixed to mast 32,with the track system defining a central mast axis 40 which defines thedirection of travel of the top drive 21. Top drive 21 may be movedlongitudinally along mast 15 by a hoisting system comprised of a winchor drawworks 20 mounted on trailer 1 and one or more cables 35 which runthrough a sheave assembly in crown block 22 located at the top of mast15. The cables 35 may extend down from the crown block and be attachedto top drive 21, whereby drawworks 20 may selectively raise top drive 21upwardly along mast 15 or lower top drive 21 downwardly along mast 15.It will also be appreciated that provision could be made to use a screwmechanism extending longitudinally along members 15 to selectively raiseor lower top drive 21 along mast 15. It will be recognized, however,that top drive 21 could be moved by hydraulic cylinders or other powereddrive member to selectively position the top drive longitudinally alongmast 15. In the embodiment shown in FIG. 1, a central axis 42 of the topdrive 21 is thus in line with the axis 40 of the mast 15 and the axis 44of the borehole or well, while the coiled tubing injector 17 has itsaxis 46 offset from the top drive axis 42. The coiled tubing injector 17may be positioned above or below top drive 21, but the centerline of thetop drive 21 is spaced from the centerline of the coiled tubing injector17.

For the embodiment shown in FIG. 1, the axes of both top drive 21 andmast 15 are always out of alignment with the axis 46 of the coiledtubing injector 17, such that the top drive and the injector may workindependently. It will be appreciated that coiled tubing injector 17 isout of alignment with the axis 42 of top drive 21, and that the axis 42of top drive 21 is in line with axis of the mast 15 and the wellbore.The threaded tubulars supported on the top drive 21 may thus be passedinto the well while the injector 17 is inoperative.

Particularly for embodiments wherein the reel 4 is supported on thecarrier 1, the injector 17 and thus the guide arch 34 are providedbetween the mast 15 and the reel 4, so that the mast does not interferewith coiled tubing operations when in the FIG. 2 configuration, and theinjector does not interfere with the top drive and threaded tubularoperations when in the FIG. 1 configuration.

In FIG. 1, the coiled tubing injector 17 is thus in an inoperativeposition while the top drive 21 is in position to manipulate threadedtubular components. With coiled tubing injector 17 out of alignment withthe axis 44 of the wellbore, the top drive 21 may perform operationstypically performed by a top drive such as, for example, manipulating atubular component such as casing brought in through the V-door, as iscommon in typical oilfield operations. Although not shown, it will beappreciated that the rig of the present invention may be provided withelevators and other components normally used to manipulate downholecomponents, e.g., to grip a pipe or other downhole component and move itto a position where it may be engaged and subsequently manipulated bythe top drive. This ability to selectively use the top drive and theinjector independently of one another is clearly advantageous in termsof saving cost and time. The rig is universal in the sense that the samerig carries a coiled tubing injector to manipulate coiled tubing and atop drive to manipulate jointed pipe or other downhole components. Theinjector and the top drive are selectively, independently operable toperform their customary functions.

Turning now to FIG. 2, the coiled tubing injector 17 is positioned overthe axis 44 of well while the axis of both the mast 15 and top drive 21are out of alignment with wellbore axis 44, and the top drive 21 is notoperable. Thus, for the embodiment shown in FIG. 2, the coiled tubinginjector 17 is being used to manipulate coiled tubing 30 and the topdrive 21 is in an inoperative position, while for the embodiment shownin FIG. 1, the top drive 21 is used to inject threaded tubulars into thewell, and the injector 17 is inoperative.

FIG. 2 also depicts a lubricator 52 positioned below the injector 17 forsealing an annulus about the injected tubular as it is run into and outof the well. One or more hydraulic cylinders 54 extending between themast 15 and the trailer 1 may be provided for pivoting the mast 15between the coiled tubing injector position as shown in FIG. 2 and thetop drive position as shown in FIG. 1. An extendable member 56 may serveas a stop to limit pivoting action of the mast 15 when the mast is inthe coiled tubing injector position. Alternatively, other stops and/orlimit switches may be positioned on the platform 12 or the mast 15 toserve the function of either a stop or to discontinue power to thecylinders 54 to stop the mast when it is in either the position shown inFIG. 1 or the position as shown in FIG. 2. FIG. 2 also depicts a coiledtubing cutting unit 6 which may be positioned on the rig floor 3 forsevering the coiled tubing at a selected location above the rotarytable, while still supporting the severed coiled tubing within the well.

FIG. 2 also depicts a support bracket 58 secured to the mast 15 and tothe injector 17 for fixing the relative position of the injector withrespect to the mast. The axis 46 of the injector is thus angled withrespect to the axis 40 of the mast 15, so that when the mast 15 istilted as shown in FIG. 2, the axis of the injector is vertical, so thatcoiled tubing may pass through the injector and into the wellbore. Aplurality of latching or locking mechanisms may be spaced longitudinallyalong mast 15 such that the top drive 21 may be held at a variety ofdesired, longitudinally spaced locations along mast 15 when the injector17 is operative.

Referring to FIGS. 1 and 2, it should be understood that the anglebetween the axis 44 of the injector 17 and the axis 42 of the top drive21 is the same as the angle of the mast 15 from vertical, so that themast 15 when vertical will have the axis 42 of the top drive 21 alignedwith the well, and the mast 15 when inclined will have the axis 42 ofthe injector aligned with the same axis of the well.

A universal rig is provided which can selectively handle and rundifferent types of pipe, coiled tubing, and other earth boreholeequipment, thereby eliminating the need for two rigs—one rig to use atop drive in the conventional manner with threaded tubulars, and aseparate coiled tubing injector rig to perform coiled tubing operations.

For the embodiments described subsequently, the same numerals are usedto reference similar components. Referring to FIGS. 3-6, a mast 15 ispivotal with respect to the platform 12, but in this case the injector17 is not fixed to the mast, and instead a vertical slide member 68 isfixed to the mast, with the axis of the slide member being vertical whenthe mast is in the coiled tubing position as shown in FIG. 3. Themechanical connection between the vertical slide 68 and the mast doesnot interfere with the travel of the top drive 21 along the mast, butdoes allow the injector 17 and the guide 34 on top of the injector to belowered and raised with respect to the mast, as shown in FIG. 3. Thisfeature allows the injector to be positioned desirably close to the rigfloor 13 when injecting coiled tubing into the well, but also allows theinjector 17 to be elevated to a higher position so that relatively longtools can be positioned between the injector and the rig floor duringservice operations. Also, those skilled in the art appreciate that themast 15 may be pivoted to a travel position so that the crown block 22is closely adjacent the front of the trailer 1. The slide member 68allows the injector to be moved to a selected location along the mastwhen lowering the mast to a position for travel of the rig to anotherlocation.

In FIG. 3, the bracket 62 secured to the injector 17 is thus slidablealong the axial length of the slide member 68, and this movement may becontrolled by a winch mechanism, by cylinders, by a chain drivemechanism powered by a hydraulic motor, or by other suitable drivemechanism 70 for raising and lowering the injector. Except as discussedherein, the other components of the rigs shown in FIGS. 3-6 may besimilar to the FIGS. 1 and 2 rig components.

Referring now to FIG. 5, the mast 15 and the top drive 21 are positionedin line with the centerline 44 of the well, so that the rig may be usedfor operations involving tubular joints with threaded ends. The axis 46of the injector 17 is spaced from the axis 40 of the mast 15, but theseaxes are parallel rather than being inclined. Bracket 58 may thus fixthe position of the injector 17 on the mast.

Rather than pivot the mast, the embodiment as shown in FIGS. 4 and 5moves the platform 12 and the mast 15 relative to the trailer 1 in alateral direction, so that the centerline 46 of the injector 17 may bepositioned in line with the wellbore, as shown in FIG. 4. Guide rails78, 88 and 90 as shown in FIG. 6 and one or more hydraulic cylinders 74as shown in FIGS. 4 and 5 may be used to laterally move the platform 12and the mast 15 with respect to the trailer 1 between the top driveposition as shown in FIG. 5 and the tubing injector position as shown inFIG. 4. When not in use, the mast 15 may still be pivoted so that themast may be lowered to a position generally over the trailer whentransporting the rig to another well site. FIGS. 4 and 5 also depict aplurality of ground engaging telescopic members 72 for reliablysupporting the trailer 1 and the equipment supported thereon when therig is in use and when the mast is being moved laterally between the topdrive position and the tubing injector position. The same groundengaging member may be used for the other embodiments described herein.

FIGS. 4 and 5 depict one or more hydraulic cylinders 74 for moving theplatform 12 and the mast 15 laterally between the coiled tubing positionand the top drive position. More particularly, the rod end of thecylinder 74 is connected to base frame 76 which slides on a top plate 78of the trailer 1, as shown in FIG. 6. Slide plate 80, rectangular framemember 82, support member 84 and support member 86 thus move as anassembly relative to the trailer. Spacer plate 88 may be secured by thebolt and nut assembly 89 between the top trailer plate 78 and the capplate 90, with the plates 88 and 90 acting as a guide during lateraltravel of the frame 76 between the tubing injector position and the topdrive position. A similar guide on the opposing side of the base frame76 provides reliable movement between the two positions. Other types ofguide rails may be provided. In the FIGS. 4 and 5 embodiments, the stopmember 56 may be eliminated, or may be used to stop pivoting movement ofthe mast when moved to the travel position.

In an alternate embodiment, a slide member 68 similar to that shown inFIG. 3 may be used in the FIGS. 4 and 5 embodiments, thereby allowingthe injector 17 to move vertically with respect to the mast. The slidemember would, however, preferably not have an axis inclined relative tothe axis of the mast, but rather would have an axis parallel to andoffset from the axis of the mast. The slide member could then be used toraise or lower the injector 17 when the mast was in the coiled tubingposition, as shown in FIG. 4.

For the embodiments discussed above, the mast 15 had a vertical axiswhen the rig is being used with the top drive to run threaded tubularsin the well, and the axis of the mast is tilted off-vertical or is movedlaterally from the vertical axis of the injector 17 when performingcoiled tubing operations. It should be understood that, in otherapplications, the axis of the mast, the top drive, and the rotary tablemay each be inclined from vertical, but these axes remain aligned withthe axis of the borehole, which is also inclined. If the borehole weredrilled so that the mast 15 was inclined 10° to the right as shown inFIG. 1, the mast may be further inclined, e.g., to 28° from vertical,when performing coiled tubing operations, since the axis of the injector17 will be aligned 15° off-vertical at this time so that the coiledtubing remains aligned with the axis of the borehole. Tilting of a mast15 from vertical is frequently done when performing certain types ofdirectional or slant drilling operations, including drilling a boreholeunder a river bed.

For the embodiment as shown in FIGS. 1 and 2, the injector 17 ispreferably fixedly secured to the mast 15 by the support plate 58 duringcoiled tubing operations, threaded tubular operations, for switchingfrom one operation to another operation. Similarly in FIG. 3, injector17 is secured to the slide 68 in a manner which allows vertical movementof the injector, but otherwise restricts movement of the injectorrelative to the slide 68. While it is preferable that the injector 17 befixed to the mast 15 for operating in the FIG. 1 or FIG. 2configurations, it is also preferable that the injector 17 be pivotablewith respect to bracket 58 when the mast is laid down for transport ofthe rig. Mast 15 as shown in FIG. 1 may thus pivot in a counterclockwisedirection, with the final travel position of the mast beingsubstantially horizontal and between the hubs of the reel 4. When layingdown or raising the mast 15, coiled tubing 30 on the reel 4 continues tobe held in the injector 17 to counteract forces exerted on the coiledtubing by the reel 4. During this operation of preparing the rig fortransport, the axis of the injector 17 preferably may pivot with respectto the bracket 58 to minimize bending forces on the coiled tubing andforces on the injector. When laying down the mast, a pin or other catchmechanism may thus be pulled to allow pivoting of the injector 17relative to the bracket 58, and thereafter the injector 17 may pivotabout an axis between the bracket and the injector. When the mast israised at a new well site for performing oilfield operations, the pinmay be reinserted or the lock mechanism activated to again fix theinjector 17 relative to the mast 58. In the FIG. 3 embodiment, it isalso preferable that the fixed position of the slide 68 relative to themast be released when laying down the mast for transport, allowing theslide 68 to pivot when preparing for transport relative to the mast 15.When the mast is raised to the activated position, the pin may beinserted or the lock mechanism activated so that the slide 68 is fixedto the mast 15. In the FIG. 3 embodiment, the injector 17 may also beallowed to pivot with respect to bracket 62. The ability of the injectorto pivot with respect to the mast when laying the mast down fortransport and when raising the mast at the new well may also be utilizedfor the embodiment as shown in FIGS. 4 and 5. The benefits of allowingselective tilting of the injector relative to the mast is particularlyimportant, however, for embodiments wherein the mast is pivoted betweenthe coiled tubing position and the threaded tubular position.

Referring now to FIG. 7, the rig 110 is provided for selectivelyinserting a coiled tubular or a threaded tubular through a rig floor andinto a well. The rig includes a mast 112 extending upward from a rigbase 114. The mast 112 is pivotally movable between a threaded tubularposition as shown in FIG. 7 wherein the centerline of the mast isaligned with the well, and a coiled tubing position wherein the injector116 is aligned with the centerline of the well. A powered drive, such ashydraulic cylinder 120, is provided for pivotally moving the mastbetween the threaded tubular position and the coiled tubing position,for laying down the mast for transportation, and for lowering the mastto pick up the injector. FIG. 7 illustrates a top drive 122 movablealong the axis of the mast to insert the threaded tubular into the well,with the top drive having an axis substantially aligned with the axis ofthe well. The injector 116 is supported on the mast, and the injectoraxis is offset from the top drive axis.

The embodiment as shown in FIG. 7 further illustrates a drawworks 124supported on the rig base for moving the top drive along the axis of themast, and a trailer 126 structurally separate from the rig base 114 andsupporting a coiled tubing reel 128 and a powered injector liftmechanism 130 discussed subsequently. The rig base 114 may thus betransferred to and from the well site separate from the trailer 126,with the injector 116 and the reel 128 each supported on the trailer 126during transportation.

Referring now to FIG. 8, the rig is shown in a position wherein the mastis substantially lowered by the hydraulic cylinder(s) 120 such that themast is positioned over the trailer 126 with the injector 116 supportedon the trailer. During transportation, it should thus be understood thatcoiled tubing extends between the reel 128 and the injector 116. Whenthe trailer 126 is positioned at the well site, the mast 112 is lowered,or if desired the lift 130 is first actuated to raise the injector, thenthe mast is lowered. In either case, the function of the powered lift130 is to raise the injector 116 off the bed of the trailer 126 to aposition such that the injector 116 may be more easily attached to themast. More specifically, attachment may be achieved with a saddle 132which is secured to the mast and engages the injector, and a poweredcylinder(s) 134, which is shown in FIG. 11, which is connected at oneend to the mast 112 and at the other end to the injector 116. Once theinjector is removably connected to the mast, the hydraulic cylinder orcylinders 120 may be actuated to raise the mast and the injectorattached to the mast to position the mast and the attached injector asshown in FIG. 7.

For the disclosed embodiment, the connector for removably connecting themast thus includes the saddle 132 and the hydraulic cylinder(s) 134, butin other embodiments may include other mechanisms for mechanicallyconnecting the mast and the injector. The powered lift 130 thus allowsfor the injector to be conveniently attached to the mast without themast interfering with the reel 128 on a trailer 126.

FIG. 9 illustrates the trailer 126 removed from the well site, and themast 112 fully lowered and disconnected at its lower end from the rigbase, so that the mast can be slid horizontally relative to the rigbase. FIG. 9 illustrates the top drive 122 preferably still mounted onthe mast, and illustrates the saddle 132 on the mast. In FIG. 10, themast is slid off the rig base, and is supported on mast trailer 140.

FIG. 11 shows a mechanism 152 for adjusting the position of the injector116 while positioned on the lift 130 so that the injector may be moreeasily connected to the saddle 132 and thus to the mast 112. In thiscase, the adjustment mechanism 152 may move the injector laterally in adirection generally perpendicular to an axis of the mast, and/orhorizontally in a generally longitudinal direction aligned with themast, so that the saddle and the injector are more easily connected.FIG. 11 shows the injector 116 with the gooseneck 117 attached thereto.The injector is supported on the lift mechanism 130 as previouslydiscussed. The lift mechanism includes a pivot member 154 pivotallyconnected to a lift base 155 and a lift top 156, a pair of hydrauliccylinders 157 are each connected at one end to the pivot member 154, andto the other end to either the base 155 or the top 156. Actuation of thehydraulic cylinders 157 may thus raise the table 156 with respect to thebase 155, and may also selectively tilt the table 156 relative to thebase 155.

To achieve adjustment of the injector 116 relative to the table 156, oneor more cylinders 158 may be provided for moving the injector to theleft or to the right as shown in FIG. 15, so that the saddle will bealigned with the injector for connecting the injector to the mast. A topplate may be attached to the table to facilitate sliding movement of theinjector relative to the table 156, and a plurality of bolt heads mayserve as stops to connect these plates. Conventional stops may be usedto prohibit the injector from inadvertently sliding off the top plate orthe table 156.

Referring to the end view of the lift 130 as shown in FIG. 12, theconceptualized injector 116 is depicted on the table 156. A pair ofcylinders 159 may be used to move the base 155 laterally in a directionsubstantially perpendicular to movement caused by the cylinder 158, sothat the base 155, the cylinders 154, 157, 158 and the table top 156 allmove laterally to align the injector with the saddle and thereby moreeasily connect the injector to the mast. Once the injector has beenproperly connected to the saddle 132, the cylinder 134 may be connectedto both the mast and the injector to support the opposing end of theinjector as it is lifted by the mast to the substantially verticalposition. In alternative embodiments, the saddle may be adjustedrelative to the mast, such that the saddle adjustment, either alone orin conjunction with an adjustment mechanism as shown in FIGS. 11 and 12,may be used to more easily connect the injector on the lift to the mast.

FIG. 13 discloses an alternate embodiment wherein the mast 112 and thetop drive 122 are positioned in line with the centerline of the well sothat the rig may be used for operation involving tubular joints withthreaded ends. The axis of the injector 116 is spaced from the axis ofthe mast to conduct coiled tubing operations. Rather than pivot the mastbetween an operative position for coiled tubing operations and anoperative position for threaded tubing operations, this embodiment movesthe mast 112 relative to the structure 114 in a lateral direction sothat the centerline of the injector may be positioned over the wellborefor coiled tubing operations, and the centerline of the mast positionedover the wellbore for threaded tubular operations. One or more hydrauliccylinders 120 are still used to lift the mast and the injector to asubstantially vertical position, and one or more hydraulic cylinders 160may be provided for moving the mast laterally between the coiled tubingposition and the top drive position. A plurality of outriggers 162 maylevel and stabilize the rig base or structure 114 on the ground. Furtherdetails regarding this embodiment are discussed above with respect toFIGS. 4 and 5.

FIG. 14 depicts yet another embodiment of the invention, with a coiledtubing lubricator housing 162 with a centerline or axis that is notcoincident with the axis of the wellbore or the mast 112, for guidingthe coiled tubing through an arc and into the wellbore. The coiledtubing injector may thus be attached to the mast when the mast islowered to substantially the position as shown in FIG. 8, and the mastwith the coiled tubing injector then raised to the substantiallyvertical position. One or more cylinders 120 are thus used to lower themast, the mast then connected to the injector, then the mast with theinjector raised to a substantially vertical position. As disclosed inU.S. Application 60/723,111, the injector may be positioned on a mastwhen it is in a substantially vertical position, and a winch then usedto raise a lubricator 162 for attachment to the injector. Alternatively,a lubricator 162 and the injector 116 may be attached as an assembly tothe mast when the position substantially as shown in FIG. 8, and themast raised to raise the injector and the lubricator. As shown in FIG.14, the central axis of the injector 116 is canted relative to the axisof the mast 112, which is substantially vertical and aligned with theaxis of the well. The axis of the lubricator 162 is slightly curved, sothat rollers, guides, or other members position the coiled tubing as itexits the lubricator with the axis of the coiled tubing being generallyaligned with the axis of the well.

Those skilled in the art will appreciate that the rig as shown in FIGS.7-14 may be revised so that in other embodiments the injector may bemovably attached to the mast and a powered drive used to raise theinjector with the mast, wherein the injector and the reel are providedon the same structure as the rig base. In still other embodiments, amast may be used to raise and lower the injector from a transportationposition to an operative position, and once the mast and injector areraised, the mast may be moved laterally with another or the same powereddrive mechanism to slide the mast between the tubing injector positionand the coiled tubing position. In still other embodiments, the mast maybe used to raise the injector supported on the same rig base as themast.

The rig as disclosed herein may be used to accomplish numerous differentearth borehole operations. In the case of employing the coiled tubinginjector, the rig may be used to drill using downhole mud motors, suchdrilling being both directional and straight hole. Additionally, coiledtubing may be used in various completion operations, such as fracturing,acidizing, cleanouts, fishing operations, using coiled tubing as avelocity string, etc. The coiled tubing can also be run as a productiontubing. With respect to typical top drive operations, conventionaldrilling can be done, casing can be run, and completion and wellservicing operations as described above with respect of coiled tubingcan also be accomplished. Additionally, the top drive can be used to runconventional production tubing.

Circulation of fluid through the coiled tubing string occurs duringdrilling and preferably during insertion of the coiled tubing into thewell, with the circulating fluid flowing between the interior of thetubing string and the annulus about the tubing string. Circulation wheninstalling a tubing string is preferable in order to better convey thestring into the well and to provide proper hole cleaning.

For many applications, the coiled tubing once installed in the wellprovides a barrier between the annulus about the tubing and the interiorof the tubing. In other embodiments, the coiled tubing is not a solidtubular, and instead may be slotted or perforated to allow fluid to flowinto the interior of the casing string.

The coiled tubing may be made from various materials, including a carbonalloy steel or a carbon fiber material. Various types of guide devices,cementing stage tools, driver shoes, packers, perforating guns,correlation indicators, and cross-over tools may be used in conjunctionwith the coiled tubing string.

The coiled tubing may be conveyed into a wellbore vertically,directionally, or in a substantially horizontal plane. Applied internalpressure within the coiled tubing may be produced with an energizedfluid or gas. Air, nitrogen, natural gas, water, compatible liquidhydrocarbons, drilling muds, and other mediums may be used for pumpinginto the coiled tubing string utilizing pumps or compressors common inthe oilfield industry.

The word “carrier” as used herein is intended to mean any structure, beit portable or fixed, whether on land or offshore, to which the mast canbe pivotally or slidably attached, which will support the mast and theattendant equipment used in the rig.

The term “rig base” as used herein is intended to mean any structure towhich the mast may be attached for support in a substantially verticalposition. The term “trailer” as used herein refers to structure which,during transportation, is separate from the rig base and is used tosupport the coiled tubing reel and the injector during transportation.The trailer may include any wheeled carrier, self-propelled or pulled bya tractor or other drive source, and may also be skid mounted fortransport. The substructure which a mast is mounted may include a wheelstructure, but also may be skid mounted.

The term “powered lift” as used herein refers to any type of powereddevice for selectively moving the injector so that the injector may bemore easily attached to and detached from the mast.

The above discussion referred to centerlines of the mast, the top drive,the injector, and the borehole, frequently referencing certain axes asbeing aligned or out of alignment at different times. It should beunderstood that when reference is made to the axes of equipment being inalignment, exact or precise alignment of the equipment axes is notrequired. Rather, it should be understood that the axes of equipmentwhich are aligned are substantially in alignment, and any misalignmentcreates no significant problems with respect to the passage of thetubulars between the equipment or the borehole.

The term “injector” as used herein is meant to refer to any poweredequipment for moving coiled tubing into or out of a well. Conventionalinjectors were discussed above and are well known in the art, but othertypes of injectors use different techniques for moving coiled tubinginto and out of the well. All equipment of the type supportable on amast for moving the coiled tubing into and out of a well are thusconsidered to be an injector. Similarly, the term “top drive” as usedherein refers to any drive mechanism positioned above the rig floor forrotating a threaded tubular. The top drive is movable along the axis ofthe mast, as disclosed herein, to insert the threaded tubular into thewell, and various types of top drives may be provided with a suitablemechanism for moving the top drive along the mast.

It will be understood, that the present invention is not limited to theuse in oilfield operations but can be used in water well drilling,mining operations, in drilling injection wells, etc. Also, as notedabove, the apparatus of the present invention is not limited to landearth borehole operations but can be used, as well, on offshore drillingand production platforms.

Although specific embodiments of the invention have been describedherein in some detail, this has been done solely for the purposes ofexplaining the various aspects of the invention, and is not intended tolimit the scope of the invention as defined in the claims which follow.Those skilled in the art will understand that the embodiment shown anddescribed is exemplary, and various other substitutions, alterations andmodifications, including but not limited to those design alternativesspecifically discussed herein, may be made in the practice of theinvention without departing from its scope.

1. A rig for selectively inserting coiled tubing or a threaded tubularthrough a rig floor and into a well, the rig comprising: a mastextending upward from the rig base; an injector supported on the mast toinsert the coiled tubing into the well, the injector having an injectoraxis offset from the mast when the injector is in an operative position;a connector for removably connecting the mast and the injector; and apowered drive for selectively raising the mast and the injectorsupported on the mast.
 2. The rig as defined in claim 1, furthercomprising: the injector and a coiled tubing reel are supported on atrailer separate from the rig base during transportation; and thepowered drive lifts the injector with the mast from the trailer.
 3. Therig as defined in claim 2, further comprising: a powered lift forraising the injector upward relative to the trailer for connection withthe mast.
 4. The rig as defined in claim 1, further comprising: at leastpart of the connector for removably connecting the mast and the injectorbeing interconnected with the mast before connection to the injector;and an adjustment mechanism for adjusting the position of the connectorrelative to the mast for interconnecting the connector and the injector.5. The rig as defined in claim 2, further comprising: an adjustmentmechanism for varying the position of the injector relative to thetrailer to align the injector with the connector for connection to themast.
 6. The rig as defined in claim 1, wherein the connector includesan injector support secured to the mast for supporting the injector whenthe mast is raised.
 7. The rig as defined in claim 1, wherein theconnector includes a cylinder secured to the mast and to the injectorfor supporting the injector on the mast.
 8. The rig as defined in claim1, wherein the mast is pivotable relative to the rig floor by thepowered drive.
 9. A rig as defined in claim 8, further comprising: thepowered drive includes one or more fluid powered cylinders for pivotingthe mast.
 10. The rig as defined in claim 1, further comprising: a slidemember supported on the mast for guiding vertical movement of theinjector relative to the rig floor; and a drive member for selectivelymoving the coiled tubing injector vertically along the slide member. 11.A method of selectively inserting coiled tubing through a rig floor andinto a well, the method comprising: providing a mast extending upwardfrom the rig base; supporting an injector on the mast to insert thecoiled tubing into the well, the injector having an injector axis offsetfrom the mast when the injector is in an operative position; removablyconnecting the mast and the injector; and powering a drive unit to raisethe mast and the injector supported on the mast.
 12. The method asdefined in claim 11, further comprising: supporting the injector and acoiled tubing reel on a trailer separate from the rig base; and usingthe mast to lift the injector from the trailer.
 13. The method asdefined in claim 12, further comprising: lifting the injector beforeconnecting the mast and the injector.
 14. The method as defined in claim11, further comprising: pivoting the mast relative to the rig floor. 15.The method as defined in claim 11, further comprising: removablyconnecting at least part of the connector to the mast before connectionto the lubricator; and adjusting the position of the connector relativeto the mast for interconnecting the connector and the injector.
 16. Themethod as defined in claim 12, further comprising: adjusting theposition of the injector relative to the trailer to align me injectorwith the connector for connection to the mast.
 17. The method as definedin claim 11, further comprising: securing an upper end of a lubricatorto the injector, the lubricator having a central axis offset from theaxis of the well to pass coiled tubing into the well.
 18. A rig forinserting coiled tubing through a rig floor and into a well, the rigcomprising: a mast extending upward from the rig floor and movablebetween a threaded tubular position and a coiled tubing position; aninjector supported on the mast to insert the coiled tubing into thewell, the injector having an injector axis offset from the mast when theinjector is in an operative position; and a powered drive forselectively moving the mast.
 19. A rig as defined in claim 18, furthercomprising: a coiled tubing guide above the injector for guiding thecoiled tubing from a reel into the injector.
 20. A rig as defined inclaim 18, further comprising: a lubricator extending downward from theinjector for sealing an annulus about the coiled tubing.
 21. A rig asdefined in claim 18, wherein the mast is mounted on a wheeled carrier.22. A rig as defined in claim 18, further comprising: a guide rail forguiding lateral movement of the mast with respect to the rig floor. 23.A rig as defined in claim 22, wherein the injector is rigidly secured tothe mast by a support bracket.
 24. A rig as defined in claim 18, whereinthe mast is pivotable relative to the rig floor.
 25. A rig as defined inclaim 24, further comprising: a slide member for guiding verticalmovement of the injector relative to the rig floor; and a drive memberfor selectively moving the coiled tubing injector vertically along theslide member.
 26. A rig as defined in claim 18, further comprising: acutting unit for severing the coiled tubing above the rig floor.
 27. Arig for inserting coiled tubing through a rig floor and into a well, therig comprising: a mast extending upward from the rig floor and movablebetween a threaded tubular position and a coiled tubing position; aninjector supported on the mast to insert the coiled tubing into thewell, the injector having an injector axis offset from the mast when themast is in the coiled tubing position and the injector is operative; aguide rail for guiding lateral movement of the mast with respect to therig floor between the threaded tubular position and the coiled tubingposition; and one or more fluid powered cylinders for moving the mastlaterally.
 28. A rig as defined in claim 27, wherein the injector isrigidly secured to the mast by a support bracket when in the threadedtubular position or the coiled tubing position.
 29. A method ofinserting coiled tubing through a rig floor and into a well, the methodcomprising: providing a mast extending upward from the rig floor andmovable between a threaded tubular position and a coiled tubingposition; supporting an injector on the mast to insert the coiled tubinginto the well, the injector having an injector axis offset from the mastwhen the mast is in the coiled tubing position and the injector isoperative; and selectively moving the mast between the threaded tubularposition and the coiled tubing position.
 30. A method as defined inclaim 29, further comprising: providing a coiled tubing guide above theinjector for guiding the coiled tubing from a reel into the injector;and providing a lubricator extending downward from the injector forsealing an annulus about the coiled tubing.
 31. A method as defined inclaim 29, further comprising: guiding movement of the mast laterallywith respect to the rig floor between the threaded tubular position andthe coiled tubing position.
 32. A method as defined in claim 29, furthercomprising: rigidly securing the injector to the mast by a supportbracket when in the threaded tubular position or the coiled tubingposition.
 33. A method as defined in claim 29, further comprising:pivoting the mast relative to the rig floor between the threaded tubularposition and the coiled tubing position.
 34. A method as defined inclaim 29, further comprising: guiding vertical movement of the injectorrelative to the rig floor when the mast is in the coiled tubingposition; and powering a drive member to selectively move the coiledtubing injector vertically.